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PREFACE
Thank you for choosin g the motorcyc le. May you enjoy riding all time.
The manual co ntains the necessary instructi ons and g uidance with respect to the o peration and maintenance of the motorcycle, and BE SURE TO
READ IT CAREFULLY BEFORE YOU RIDE TH E MOTORC YCLE . Proper operation and maintenance can guarantee a sa fe riding to minimi ze lroubles
of the motorcycle and keep it in a sound condition, whi ch can extend the engine service life.
All rights reserved. No part of this publi cation may be reproduced without our prior written permi ss ion.

IMPORTANT NOTICES
• Operator and Passenger
Thi s motorcycle is designed to carry the operator and one passenger. The max imum load weight of the motorcycle must not exceed 150kg .
• On·road
Thi s motorcycl e is designed for on-road use.
Pay special attention to statements preceded by the fo ll owing words:
.&WARNING: Indicates a strong possibility of severe personal illjury or death if illstructions are lIotfollowed.
.t.t,CA UTION: Indicates a possibility of equipmellt damage if illstructiolls are Iwt followed.
NOTE: Gives helpful information.
E nvironmental Protection (EP) : Indicates special precautions that must be taken to meet environment protection laws and regulations.
Improper use of a motorcycle may cause environment pollution.
If the o perator fail s to fo ll ow safe o perating and maintenance practices. the Co. will not take any responsibility to an y inj ury or dam age occured.
Thi s manual should be considered as a permanent part of the motorcycle and should remain with the motorcycle when resold.

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 CONTENTS
MOTORCYCLE SAFE RIDING Engine Oil (Ep) ..................................................... 10
Safe Riding Rules ................................................... 1 Clear away Carbon Deposi t (EP) ........................... 10
Protective Cloths .................................................... 1 Spark Plug (EP) ...................................................... 10
Refitting ... ................ .......... ................ ....... I Air C leaner (EP) ..................................................... 10
Loading .. ............... ............ ... ..... I Valve Clearance ..................... .................................. II
Accessories ............ ... .. ... ..... . 1 Cam Chain Adjustment ........ ...................... ......... .. II
GENERAL INFORMATION Mumer (EP) ..... ......... .. ......... ..................... ............ II
Pans Location ............................... . ... 2 Electroni c-Operated Aerati on System (EP) ........... 11
ViN Record ........... . ....... 3 Operation of Throttl e .......... ................................... II
Fuel and Engine Oil (EP) . ........ 3 Idle Speed of Carbureto r (EP) ............................... 12
CONTROLLING PARTS Check Leaks alo ng Air Supply (EP) .............. ...... ... 12
Meter and lndicators . .......... .. ... ..... .. . .. ....... 3 C lutch ............................................................. ........ 12
Ignition Switch and Steering Lock ............ ......... 4 Dri ve Chain ........................................................... 12
Ri ght Handlebar Controls . .................................... 4 Front Brake ........................................................... 13
Len Handlebar Controls ..................... ... 4
Rear Brake ... .... ..... .......... ,.. ......... 13
Choke Lever ... ..... .. ... .... .. . ....... .. ... ......... 4
Brake Li ght ....... ............................................. ........ 13
Refueling and Cap ....... . .. ..... ... ..... . .. 5
How to Use Brake Wear Indicator ............. ........... 14
Fuel Cock .......... .... ............. ..... ....... ... ..... .. .. 5
FrontlRear Shock Absorber and Suspen sion .......... 14
Gearshift Pedal ........... .................. ..... ...... .... ........ 5
Tyre ........................................................................ 14
Rear Brake Pedal.......... . ..................... ............... 6
Front Wheel ...... .... ...... .......... .... .... ...... .... ........ .... .... 15
Rear Shock Absorber ........ ....................... ..... ......... 6
Stand. . .. ....... .......... .... ......... .......... ..... ......... 6 Rear Wheel ...... ...... .... ... .. ... ...... ..... .... ...... ..... 15
OPERATION GUIDE Fuse ............. .............. .......... ......................... .. ........ 15
Pre-ride inspecti on .......................... .............. 7 Battery (EP) .................. .... ..... ............. ..... ............ 15
Starting Lhe Engine ... ... ................. .......... ......... 7 TROUBLESHOOTING, STORAGE AND OPTIONAL PARTS
Breaking-in ....... . ...................................... 7 Troubleshooting ..................................................... 16
Riding ..................... . . ....... ........ ... 7 Cleaning and Storage ............ ................................... 16
Braking and Parking .... .. .... ... .. ... .. .... ... ..... .. .. 8 Removal from Storage .......... .... ......... ....... ... 16
MAINTENANCE Anti -the Ft Dev ice (Optional) ................................. 16
Tool Kit ................................................................ 9 ELECI'RICDIAGRAM .............................................. 17
M aintenance Schedule ........................................... 9 SPECIFICATIONS .................................................... 18

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 MOTORCYCLE SAFE RIDING
SAFE RIDING RULES
~ WARNING Motorcycle riding requires special elTorts on your part
to ensure safety. Know these requirements before you ride.
• A lways make a pre-ride inspection before you start the engine. You may
prevent acc ident or equipment damage.
• Most countries require a special motorcycle riding lest or license. Make
sure you arc qualified before you ride. NEVER lend your motorcycle to an
inexperienced rider.
.M ake yourself conspicuous to help avoid the accidenllhat wasn't your
fault:
• Wear bright or renecli ve clothing.
• Don't ride in another motorist's "blind spot".
e Don'1 speedily cross another's way .
• Obey all nalional and local laws and regulations.
• Obey the speed limits, and NEVER travel faster than cond itions warrant .
. Signal before you make a turn or lane change to draw other motori sts '
attenti on.
. Use extra caution at intersections, parking lot en trances and exits .
• Always re member to ride with both hands and keep both feet on the rider
footrest while the passenger grasps the handrail with both feel on the rear
footres t.
PROTECTIVE CLOTHS
• For the safelY sake. always wear a helmet, a face shield. dust glasses and
prOlective clothing. Your passenger needs the same prOlection.
• The exhausl system becomes hot during operation. and it remains hot for
a while after stopping Ihe engine. Tak e care nOI to tou ch the exh aust
system whi le it is hot. Wear clothing that fu ll y covcrs your Icgs.
. 00 not wear loose clothing that could catch on the control levers, whee ls,
etc.
REFITTING
&. WA RNING Ar bit rarily refitti ng the motorcycle or removing th e
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original parts may make riding unsafe, and is illegal also. The user
must obey all national and local laws and regulations in relation to
vehicle and trame. If you have a good proposal concerning refitting of
the motorcycle, please write us. The refitment can be done with per-
mission of the Co. Otherwise, the user will take the consequences.
LOADING
L!l. WARNING Addition of accessories and cargo may reduce the
motorcycle's stability, performance and safe operating speed.
.Keep cargo and accessory weight lower and close to the cenle r of the
motorcycle. Load weight equally on both sides to minimize imbalance. As
weight is located further from the motorcycle's center of gravity, handling
is proportionally affected .
• Adju st tyre pressure and rear suspension to suit load weight and riding
conditions .
• Make sure thai cargo is fastened on the vehicle .
. 00 not attach items to the handlebars. fork or fender. Otherwise, unstable
handling or slow steering response may occur.
. The maximum load weight of the motorcycle is 150kg. Please do not
overload.
ACCESSORIES
Genuine accessories of the Motors have been specifi ca ll y designed and
tested on the motorcycle. Beacuse the factory cannot test all orner accessories.
you are perso nally re-sponsible for selection , installation and use of acces
sori es not produced by the Co. AI-ways follow Safe Riding Rules and these
below:
. Carefu ll y inspect lhe accessory to make sure lhat it does nOi obscure ::my
lights, reduce ground clearance or banking angle, or limit suspension travel,
steering travel or control operation .
• 00 not install olher cooling equipment for the engine.
. Do 110t add electrical equipmenlthat will exceed the mOlorcycle's electri-
cal system capac ity .
 GENERAL INFORMATION

PARTS LOCATION (Fig.I.2l

Fi g. I (Left-v iew) Fig.2 (Right-view)

CD Meter ® Fr. wi nker @ Headlight @) Gearshift pedal CD Rearview mirror ® Fuel tank @ Taillight ® Exhaust muffler
@ Side stand ® Rr. shock absorber ® Pillion footrest @ Driverfootrest CD Rr. brake peda l
® Fr. shock absorber

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VIN RECORD (Fig. 3-5) Engine oil must be selected in accorda nce w ith rul es below a nd o th e r o ils,
such as ordinary engine o il. gear oil and vegetable oil , are fo rbidde n to be used .
The vehicl e has been fill ed with e ngine oil S A E 15W/40· S E be fore bein g
deli vered . The lubri cant is onl y suit abl e al a
te mpe rature ran ge within - IO 'C ........ +40 'C. lf
olhe r motor oilis 10 be used instead, the alle r· •
Fi g.3 Y IN Fig. 4 Engine code Fig. 5 Nameplate •
nali "e must be technically equivalent in every
YIN : I I II I I I I respect. Vi scos it y va ri es w ith regio ns a nd
Enginccodc: II I I III te mpe ratures, so the lu bricant has to be se-
Please fill the VIN and e ngi ne code of your motorcycle in the bla nk below. lected according to our recomme ndation.
They w ill he lp o rde r spare parts a nd fin d out the vehicle when stolen. If there is no gasoline e ngine oil SAE I 5W /40- ·30
D 102D3OCI!ID'C

NOT ES SE. the engine oil No. HQB- IO (or HQB-6 in Fig. 6
CD The Y IN is sla mped o n the ri ght of the steering ste m (Fig. 3). regions whe re the te mperature is lower than -

(%) The e ngi ne code is stamped o n the botto m-left o f the crankcase (Fig. 4). IO'C ) can be used instead.
<ID The vehicle nameplate is fixed on the left o f the steering stem (Fig. 5).
FUEL AND ENGINE OIL (EP) CONTROLLING PARTS
Fuel Selection METER AND
Fuel is a key factor in dec iding the e xh aust e mi ss ions from the e ngine . so INDICATORS (Fig. 7)
selection or fuel must follow the rules bel ow. Selected fuel mu st be unleaded CD Speedo mete r
gasoline with octane No. RQ-93 or highe r. Using improper fuel could reduce CD Odome te r
performance. shorten the engine's servi ce li fe. Q) Righi turn signal indicator " .,.."
Engine Oil Selection (Fig. 6) ® Left turn signal indicator " .."
Thc qualily of the e ngine oil plays a vital role in decidi ng the engi ne pertonnance ® Hi-beam ind icator "

and service.

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IGNITION SWITCH AND STEERING LOC K (Fig. 8) Lighting Switch
The 3-posi tion switch functions as fo ll ows:
Igniti on Switch
:Thc headl ig hl. tai llight and meter lights arc bright.
The ~ w i tc h is equipped wi th 2 keys incl uding
FE : The parking light. tuil ight and meter lights are bright.
a spare one. • : (OFF) The headlight. tai lli ght. parking li ght and meter light s are off.
" , ~, " OFF: Engi ne and li ghts ca nn OI be Emergency Switch
operated and the key can be removed. In an emerge ncy, deprc\sing the switch to~ ' J' '' will stall the eng ine at once.
In nomla! riding cases. always set the swi tch at "0 ".
""0 " ON: Eng ine and lights can be operated. Fig.8 Steering lock Throtll e G rip
neutral light is lit and th e key ca nnot be 111e grip is used loconlrol engi ne power. Turning inlhe grip will increase fu el
removed. suppl y, while turn ing out it will decrease fuel supply.
Parking LEFf HANDLEBAR CONTROLS (Fig. 10)
(nsen the key i nto the lock core, and pres\) it w hile turn ing cou nl erc l oc k w i ~ Head lig ht Dimmer Swi tch
Pus h the switc h to '" .. to se lec t hig h
[0 •• p,. position. then remove the key. In th is casco the ta illi ght and parki ng
beam.
li ght wi ll glow. and engine and other lights cannot be operated. To c.. nccl the
Pu sh the sw itch to M .. to selec t lower
cond iti on. tum the key clockwise to o ther position. beam.
OTE When the vehicle is nOI kept in use, always . . cl the switch to "OFF ' Tu rn Signa l Switch
and re move the key. Move the sw itch to ~ ~ " to signal a left
Steering Lock tum. to .. ~ .. to signal a ri ght tum .
To lock the steeri ng head. turn left the s teering Horn Button Fig. 10 CD Dimmer sw.
Press the butto n .. b- .. to sound th e <D Turn signal sw.
bar as far as it wi ll go. [urn clockwise the ignition <» Hom button
hom.
key until locking the steering bar. at last remove
Passing Signal Switch .. (Fig. II)
the key. To un loc k the steeri ng head. turn the Passing signal sw.
When pass ing. press and release the
key countercloc kwise. <D Starter button switch, the headl iglll wi ll wink to warn the
RIGHT HANDLEBARCONTROLS <D Lighting sw. vehicles.
:l) Emergency sw. CHOKE LEVER (Fig. II)
(Fig. 9)
® Thrott le grip T he c ho ke leve r is loca led o n the left
Starter Button
Fig. 9 hand lebar contro ls. Pu sh the lever to open Fig. 11 Choke lever
Depress the bu tton "'1)" to start up the eng ine.
-1 the thrott le.
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REFUELING AND FUEL FILLER • The fucl cod.. is located m the left-bollom of the tank. With the fuel cock
CAP (Fig. 12) in "OFF" position. fue l cannot now from the tank to the carburetor. Turn
• Open the lock lid, and inser1 the ignilion key; the cock to OFF whenever the motorcycle is not kept in use .
• Tum the key clockwise by 90 ° • With the fuel cock in "'ON" posillon, fuel will Dow from the main fuel
• RC'TIove the cap. sypply to the carburetor. With lhe cock in "RES" position, fuel will now
To reinstall the cap, just depress it onto the tank rrom the reserve fuel supply to the carburetor. Use the reserve ruel only
inlet. The fuel tank capacity is 14 L including when the main supp ly is gone. Refill the tank at the earliest opportun ity.
Lock lid Fuel filler cap
the reserves supply of 2 L. LhCAUTION After refueling, make sure that the fuel cock is in ,. ON"
Fig. 12
LtWARNlNG position. If it is in" RES" position, you may run out of fuel with no reserve.
• Do not overfill the tank (there should be no fuel in the filler neck) . Correct use of the fuel cock can avoid the state above-mentioned.
After refueling, make sure the I'uelliller cap is closed securely. GEARSHIFT PEDAL (Fig. 14 & 15)
• Gaso line is extremely flamm a ble and is explosive unde r certain Th e motorcycle is equipped with a 5-speed mesh transmission. The gear
conditions. Refuel in a well-ventilated area with the engine stopped. indicator shows the gear position at present.
Do not smoke or allow flames or sparks in the area wh ere the fuel Fig. 15 shows a gear pattern.
tank is refueled.
• Before refueling, make sure to filter fuel first. Spilled fuel vapor
may ignite. If any fuel is spilled, make sure the area is dry before
starting the engine.
FUEL COCK (Fig. 13)
forbidden to
gea rs hift up or
Cl ow n when the 1
0 (r-'
Gea r s hift is .<?)-(s)

throttle is sti[] not ,

decreased and the t::\
0
1':\
/
clutch is ill. 0 _ \V

Internait iona 5-speed

Fig. 13 Fig. 14 Fig. 15

··OI·P "RES "

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REAR BRAKE PEDAL (Fig.16) SIDE STAND (Fig. 18)
When parking the vehicle, turn the side sland clockwi se along the frame to
The rear brake will function and the rear stop
position. Before driving the vehicle, seL the stand to the initi al pos ition.
light will g low when treading the pedal.
CAUTION Be sure to set the stand to position before driving the
Fig. [6 Rr. brake pedal motorcycle. Otherwise, it may fall over.

REAR SHOCK ABSORBER (Fig. 17)

The shock absorber has 5 adjustment posit ions for different loads or riding
conditions. Position I is for light loads and smooth road conditions. Positions
II to V increase spring preload for a st iffer rear sus pen s ion , and ca ll be

used when the motorcycl e is heavil y loaded or ridden in rugged roads. Use

a pin spanner to turn the adjuster to proper position.

Fig. 18
NOTE Be sure to adjust shock absorbers both le ft and right 10 the same
position.

Fig. 17 D m IV V

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 OPERA TION GUIDE
PRE-RIDE INSPECTION
Inspect your motorcycle every time before you ride it. The items listed here
wi ll only take a few minutes to in spect. and in the long run they can save
time. expense, and possibly your life.
1. Engine oil level- add eng ine oil if required . Check for leaks.
2. Fuel level- refucl when necessary. Check for leaks.
3. Front and rear brakes - check operation. and adju st free play if necessary.
4. Tyres - check cond it ion and press ure.
5. Battery electrol yte - check that the electroly te is suitable.
6. Thronle - check for smooth opening and full closing in all steeling positions.
Adjust or replace it if necessary.
7 . Lights and horn - check lhat head li ght. tail/slop li ght. w inkers. parking
light , indicalOrs and horn function properly.
8. Drive chain - check condition and slack. Adjust and lubricate if necessary .
9. Fasteners - check that all nuts, screws and bolt s are mounted securely.
10. Steering system - check for it s smoothness and reliability .
STARTING THE ENGINE
CAUTION Do not start the engi ne in a narrow area to prevent accidents.
Attempting to start the engine with the tran smission in gear may result in
damage to equipment.
Before starting, confinn the following:
.Make sure the fu el in the lank is enough. Set fuel cock to "ON " position.
\.. • In sert the ignition switch and turn it to "0 " position.
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• Move Ihe gearshifl pedal info NEUTRAL 1o lighl up Ihe indicalor .. ~ .,
(green),
• Sel the choke lever to the fully closed pos ition if the engine is cold .
• With the throlll e sli ghtl y open (less than liS of ils entire opening), oper
ale the sl'H1er so as to start the engine. Then push choke lever to half-open
pos iti on.
• Warm up the engine entire ly at an idle speed of 1300r/min until il works
normally, and then push the choke lever to its fully open position.
NOTE
Do not use the electric starter fOI' more than 5 seconds at a time.
Release the starter button for approximately 10 seconds before press
ing it again.
BREAKING-lN
Help assure your motorcycle's future reliability and perfonnance by paying
eX ira allenlion 10 how you ride the first IOOOkm. During this period avoid
full lhrottle riding. be sure to drive at a speed no more than 80% of each gear
and 10 co ntinuall y chang in g s peed. After the break-in period , be sure to
conduct maintenance so as to make co mpen sation for initial wear. The se r-
vice life will be extended obviously through such maintenance.
RIDING
• Start the engi ne and warm up it.
• While the engi ne idling, pull in the clutch lever and push down the gear
shift pedal to shift into low ( I st) gear.
• Slowly release the clutch lever and at the same time graduall y increase
engi ne speed by opening the throttle.
1 • When the motorcycle atlains a steady speed, close the throttle, pull in the
cl utch lever and shift to 2nd gear by treading the gearshift pedal.
Thi s sequence is repeated to progressively shift to hi gher gears.
• Coordin ate the throttle with brakes fo r smooth deceleration .
• Both front and rear brakes should be used at the same Lime and sho uld not
be applied strongly enough to lock the wheel. or oraking e ffectiveness will be
reduced and control of the motorcycle be di ffic ult .
CAUTION
It is forbidden to gearshifl up or down when the throttle is still not decreased
and the cl utch is in. Otherw ise, damage to the engine, chain and other parts
may occ ur. Make sure the gearshift peda l is operated ge ntly and exactly.
Riding with your foot restin g on the brake peda l may suddenly change a
speed and/or damage the d riving mechani sm.
BRAKING AND PARKING
To stop the motorcycle, close the throule and disengage the cl utch by pulling
in the cl utch lever. then smoothly o perate the fro nt and rear brakes until
stoppi ng the motorcycle.
Sh ift the transmission into neutra l, turn the e merge ncy sw it ch to ..~ "
pos iti on. The n set the fue l coc k to "OFF" pos it ion, su ppo rt the motor-
cycle with the center or side sland. After parking, turn the ignition switch to
"jg!" pOS itio n and lock the steering lock. followed by remov in g the key.

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 MAINTENANCE
TOOL KIT (Fig. 19) ~E
ITEM
ODOMETER READING, km (Note Q) )
fiN. 4.00Ok. 8.000lm 12.0001..m Remarks
1.000km
Some road s ide repai rs, m in or adju stments and part s re placement can be
perform aced wi th the tools available in the kit. • Fuel line sys tem I I I
CD Screw driver grip • Fuel filter C C C C
Q) Double-end screw driver stem • Throttle operation I I I I
Q) Spark plug wrench • Carburetor choke I I I
® Slip-jointed pliers Air cleaner element Note CD C C C
® Open-ended spanner. 8 x IOmm Spark plug I I I I
® Open-ended spanner. 12 x 14mm • Valve clearance I I I I
CD Open-cnded spanner, 13 x 15nun Engine oil Yearly
Fig.19 R Every 2.000km-R
® Open-cnded spanner. 17 x 19mm
Engine oil Slrainer Yearly·R C
® Allen key . i'5
<Ill Allen key. =6 • Cam chain slack A A A A
® A lien key, =8 • Engine idle speed I I I I
@ Toolbag Drive chain I.L I.L 1. L 1. L
Battery Monthly I I I I
MAlNTENANCESCHEDVLE
Brake shoes/pad wear I I I
Maintenance work should be performed in light of Maintenance Schedule.
leiters in the table indicate as follows: Brake syste m I I I I
I: INSPECT AND CLEAN, ADJUST. LUBRICATE OR REPLACE IF • Brake light switch I I I I
NECESSARY • Headlight adjustment I I I I
C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE Clutch I I I I
* The item should be serviced by your dealer, unless the owner has the Side st:md I I I
proper tools and is mechan ically qualified. Refer to the manua l. • Suspension I I I I
** In the interest of safety, we recommend these items should be serviced
on ly by you r dealer.
NOTES: <D C lean more frequently when riding in unus ual wet or du sty
....
• Nuts. bolts. fasteners
Wheels/spokes
Steering bearings
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I
I
I
I
I
I
I
I
I
area'i.
m Al higher odometer read ings. still follow the frequency in terva ls estab-
li shed in this manual.
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ENGINE OIL (EP) CLEAR AWAY CARBON DEPOSIT (EP)
C heck of Eng ine Oil (Fig. 20) C lear away carbo n deposi t around the spar k plu g and pisto n ring. o n the
Check the engi ne oil level before every piston top. in the piston ring slot and combustion chamber regu larl y.
usc. SPARK PLUG (EP) (Fig. 22)
• Place the motorcycle on a level ground Spark Plug Type' A 7TC
and keep it in vertica l position. Then Check and Replace
start the engine and run at id le for a . Disconnect the spark plug cap from the spark
few minutes. plug. Clea n any dirt from around the spark
• SlOp the engine so as to let the oi l Fig. 20 plug base. Remove the spark plug by the
level be stab le. Check the oi l level spec ial wrench.
CD Oi l filler cap
throught the sight g lass located at the . Inspect the electrodes and center porcelain
lower of the righ t crankshaft case.
<» Upper level mark
Q) Lower level mark
for deposits. i.lIld clean with a wire brush. If
• The level must be maintained be- the spark plug is damaged, replace it.
Side electrode
tween the upper and lower level marks. . Check the spark plug gap which should be O.
Add Lhe engine oil if necessary Fig. 22
7 ± 0.1 mm. and adjust by bending the side
CAUTION Running the engi ne with ins ufficie nt oil ca n cause seri- electrode if necessary. T
ous da mage to the engine. AIR CLEANER (EP) (Fig. 23)
Change of Engine O il (Fig. 21) The air cleaner must be cleaned and then soaked in clean oil alleast once every
e lt is better to drain when the engine is still wamlcd. 4000km's drive. Riding in very dusty area, Lhejob should be done more often .
• Place an empty container under the engine, See your dealer for further information.
unscrew the drain plug.
• Remove the right side cover. Loosen off
. T read the kick-starter pedal several
times so as to help empty the oillhorough ly. screws. Remove the air cleaner cover. Take
• Reinstallthe drain plug, and lighten it up. the element out of the housing .
". Pour approx. I L of SAE I5W/40-SE into • Wash the element in cleansing solvent and
the crankcase. Restart the engine, keep it idle dry it.
for a few minutes, and then stall it. Recheck Fig.2 1 Drain plug • Soak the elemen t in gasoline eng ine oi l
the oil level, and add oil if necessary. SAEI5W/40·SE unti l saturated. and squeeze
CAUTION When runnin g in very dusty conditi ons, oil chan ges out the excess oil.
sho uld be performed mo r e freque nll y than s peci fcd in lhe nUlint e- • Re ins tall all the removed pa rt s we ll in the Fig. 23 Ai r cleaner
nan ce schedul e. reverse order of remova l.

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VALVE CLEARANCE
Excessive valve clearance w ill cause noise and eventual engine damage. Little

or no clearance will prevenllhe valve from clos ing and cause the damage 10
valve and loss of power. Check valve clearance when the engine is cold at the

spec ified intervals.See your dealer for thi s service.

EXHASUT MUFFLER (EP)
Clear away regul arl y carbon deposit in the ex haust pipe; check the ex haust
pipe in side for crack and washer damage, and repari or replace if necessary
SCHEMATIC DRAWING OF JL CORE TECHNICALSYSTEM
ELECTRONIC-CONTROLLED AERATION SYSTEM (EP)
Fig. 24
WORKING PRINCIPLE (Fi g.24)

Based on advanced thin combustio n in the gasoline engine and eleclro nic-
comrolled theory, adjust the dutycycJe of EGR valve at realtime by collecting
rotatory signal with ECU and control the ai r now through EG R va lve, as a
result, achieving dynam ic adjuslion of aeration, controll ing air/fuel mi xture
from the carburetor and improving fuel suppl y of carburetor.
OPERATION OF THROTTLE (Fig. 25)
• Check for smooth rotation of the throttle
grip from the fully open to the full y closed
positio n at both full steering pos ition .
• Meas ure the throttle grip free play at

FEATURES the thrott le grip flan ge. The standard free

play sho uld be approx. 2-6mrn.To adjust
I. By adoptin g e lectronic-controlled technology, the engi ne can ru n aI an
the free play, loosen the lOCknut , tum the Fig. 25
optimal ai r/fuel mixture so as to make it not on ly more powerful, lower fuel CD Throttle grip
adju ster. Adju stm ent over. fasten the
consumpti on, bu t also lower exhaust emissio ns. <D Locknut
locknut. Q) Adj uster
2. The electroni c-controll ed system consists of an ECU, an EGR va lve and
lines etc, is characterized by easy installat ion and reliabl e performance.

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IDLE SPEED OF CARBURETOR (EP) (Flg. 26)
• The carburetor is maumed between the engine and the air cleaner. <D
NOTE
The carburetor has been sct accurate ly in factory. The user only needs to CD Locknut "./~x~~
. ;( ~~
adjust idle speed afler the engine is warmed up. a:., C lutch cable holder
• Adjust idle speed with the throlLle SlOp screw 10 SCI idle speed at aboul
<ll Bool
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1300r/min. Tum the screw in direction A will increase idle speed. in directi on Fig. 27 ,-
B decrease idle speed .
• When the engine has no idle speed or runs at DRIVE CHAIN (Fig. 28)
a decreased speed, set the thrOille SlOp screw Check
in the middl e between the two limit pos i. Check the drive chain for wear and slack. Lubricate the chain if it !o,eems to be
lions to he lp mix air and fuel. dry.
• Make a trial. and readjust the throttle stop Throttle SlOp screw Slack should be I 0-20mm . Support the motorcycle with the center stand.
screw, if necessary. Fig. 26 check slack in the lower chain run midway between the sprockets.
CHECK LEAKS ALONG AIR SUPPLY LINE (EP)

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C hec k reg ularl y air su ppl y lin e. spec ially s uch as the joint between the
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mufner and engine. the joint between the air cleaner. carburetor and in let

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pipe. etc. for leakage, and repair or replace damaged parts once there are some
troubles to assure a normal air suppl y.
ADJUSTMENT OF CLUTCH (Fig. 27) IO-20mm Chain clip

. Measure the clutch lever Free play at the clutch lever flan ge. The free play
s hould be IO ....... 20mm. Adjustment of the clutch should be done with the Fig. 28
engi ne stalled. (D Chain mRear axle locknut
.Tum loose the locknu t at the clu tch cable ho lder located on the crankcase. <ll NUl @) Adjust ing bolt
(2) Index mark @ Chainclip
and then make adjustment by screwi ng in or out the correspond ing adj usting
nul. After adjustment. Lighten up the lock nut.
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Adjustment Place the motorcycle on the level ground. Check the brake Ouid level thrOugh",
Loosen the rear axle nut and locknut, turn both adjusting bolts until the chai n the sig ht glass. If Lhe fluid level is below the LOWER , loosen the cyli nd e r I
slack meets the standard, and make sure left and right adjusters al ign with the cove r screws, remove the ule cover, add brake fluid up La the UPPER level
same index marks. After checking. tighten up the rear axle nut with a torque mark.
of 50 - 60N.m.
Lh WARNING Brake fluid may cause irritation. Avoid contact with
NOTE Turning the adjusting nut in direction A wi ll increase the chain slack,
skin or eyes. In case of contact, flush thoroughly with water and call a
and in direction B decrease the s lack.
* Check the chain for slack
doctor if your eyes were exposed. Apply specified brake fluid , or brak-
* If slack of chain is changed, it is necessary to relocate Lhe rear wheel, for
a:djustment wi ll affect the rear brake pedal free play.
ing effectiveness and riding safety will be affected adversely. Do not
allow contaminants such as dirt or water to enter the brake fluid tank.
Lubrication Adjustment
Pullout the chain clip with pliers, remove the joint and chain. Wash the chain The free play should be IO-20mlll. Adjust it as follows if necessary:
in cleansing so lu tion and dry it in the air. Check the chain including lin k Pump the brake lever, then gently loosen the bleed valve while holding the
plates, bushings. and rol lers for damage, cracks, wear-out. Replace if necessary. lever. Take care to lighten lip the bleed valve as soon as flowing fluid. Repeat
Lubricate the chain, then reinstall and adjust it. above procedure until the system is completely bled.
CAUTION The cha in clip should be so installed as to make sure thaL its Apply the brake several times and check for free whee l ro tati on after the
closed end faces the direction of wheel rotation.
brake lever is released.
FRONT BRAKE (Fig. 29 & 30) REAR BRAKE (Fig. 31)
Check Fig. 29
The fronL brake cylinder is located on the right
handlebar.
When operating the brake lever, the pads Fig. 31
equipped with cali per will c lamp the brake disc. CD Rr. brake pedal
If any pad is worn to its limit depth, replace Fr. brake lever Q) Adjusting nut
bOLh pads as a set all the first opportunity.
Wear limit
Fig. 30 Support the vehicle o n its side stand. Measure the distance the rear brake
CD Main cylinder pedal moves the brake starts to engage. The free play shoul d be 20 - 30ml11.
m Sighl glass
To adju st, turn the rear brake adjust in g nul. Turning it clockwise will de-
(J) Screw
® Cover crease the free play, and counterclockwise increase the free play. Apply the
(i) Brake caliper several Limes and check for free wheel rotation after the brake pedal is released.
3
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ADJUSTMENT OF BRAKE LIGHT SWITCH (Fig. 32)
The rear brake light switch is lo-
cated on the right of the vehicle. If
the switch operates too late. turn
the nut in direction B: if the switch
operates loO soon. tllrn the nUL in
direction A.
HOW TO USE BRAEK WEAR INDICATOR (Fig. 33 & 34)
Should either pads of front brake be worn 10
pads as a set as soon as possible.
The rear brake is equipped with a brake wear indicator. If the indicator al igns
with the reference marks on full applicat ion of the brake. the brake shoes
must be replaced.
Fig. 33
Q) Fr. brake disc
'w Q) Fr. brake caliper
Q) Fig. 34
CD Rr. brake panel
@)
Q) Reference mark
Q) Indicator
® Rr. brake ann
FRONTIREAR SHOCK ABSORBER AND SUSPENSION
Support the motorcycle on the center sland , pull in the frollt brake lever to
lock the front wheel. pump the front/rear shock absorber up and down
several times to see that it runctions well without noise or leakage. Check the
rear rork bushing for proper play by pressi ng the side of the rear wheel.
brake light sw.
Make sure that all of the fasteners are tightened securely.
TYRE
Proper air pressure will provide maximum stab ility, riding comfort and pro-
long lyre li fe.
TYRE PRESSURE
the limit depth, replace both
Rider (kPa) Fronl tyre: 200 Rear tyre: 225
Rider & passenger (kPa) Front lyre: 225 Rear tyre: 250
Tyrc Size Front lyre: 3.0-18 Rear lyre: 5.0-15
WARNING Operation with excessively worn tyres is hazardous and
will adversely affect traction and handling.
NOTE Tyre pressure should be checked before you ride while the tyres are
Wearlill1iL ]
';cold". Check the tyres for cu ts. embedded nails, or other sharp objects.
Check the rims for dents or defonnalioll. See your deler for change or damaged
lyres or punctured inner tubes.
CAUTION Improper tyre innation will cause abnorma llread wear and
creale a safety hazard. The lyre presse less Ihan the rated value may result in
slipping wheelan the ground or coming off from the rim.
When the tread depth in the middle sect ion or lyres reached limits below.
please replace them.
TREAD DEPTH LIMITS
Fro nllyre I 1.6mm II Rear lyre I 2.Omm
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/
FRONT WHEEL (Fig. 35)
Support the motorcycle firmly before re-
moving the front wheel.
Loosen the front axle nul. extract the front
axle, and remove the front wheel.
L!>.CAUTION The suppon should be so
heigh and fast as to avoid the vehicle turning
over.
REAR WHEEL (Fig. 36)
Support the motorcycle, unscrew the rear brake adjusting nut , lake the link
out of the brake arm. Loosen the lock nuts at both s ides of the rear wheel.
then loosen the rear axle nut and adjusting bolt.
Take oUllhe chain clip by pliers, remove the chain and rear ax le nut. retract
the rear ax le. at last. remove the rear wheel.
NOTES
Installation shall be done in the reverse Of-
der of removal.
Tightening torque o f rear axle nut: 50-60N.
m Adjustment of rear brake and chain: refer
to related items in the manual.
L!>.CAUTION The suppon should be so
heigh and fast as to avoid the vehicle tuming
over.
FUSE (Fig. 37)
The fu se is positioned behind me left cover
near the battery stay. The fuse will blow to
protect the circuit aUlOmalically in the case ~
of rroubles suc h as a short circui t or an over-
load trouble. After the troubleshooting, fi t a
new fu se available in the fu se box .
BATTERY (EP) (Fig. 38)
The battery is located behind the le ft cover o f
Upper level mark
vehicle, Maintain it in accordancde with the Main-
tenance Schedule in the manual. The ballery elec-
Fr. axle tro lyte level should be between theUPPER level
mark and LOWER level mark. Should battery
Fig. 35
electrolyte level be below the LOWER level mark.
add proper distilled water to the UPPER level
mark. Becareful not to exceed the UPPER mark Lower level mark
when adding distilled water, otherwise, overnow-
ing electro lyte may cause corros ion . Fig. 38
&.ATTENTION Be sure no t to di scard the ballery electrolyte or used
battery. Hand le in accordance with national or local environmental protection
rules. Avoid entering water around the ballery when washing the vehicle.
£t.WARNING If the battery is 10 be removed. disconnecllhe negati ve lead
" ,. from the battery terminal first. and then the position lead "+". Connec-
Adjusting nul lion should be done in the reverse order of removal. Do nOltouch the positive
Fig. 36 lead with the vehicle body to prevent short-ci rcuiting. The leads should be
tigh tened securely, or spark may occur to cause a fire. Make sure that the duct
of battery keeps unblocked. or the battery may be explosive under certain
Locknut
condi ti ons. The battery , in addition, should be equ ipped with an exhaust
Brake link pipe. otherwise, overflowing eleclrol yte (sulfuric ac id) may erode the vehicle
body, main cable. even causi ng a fire by short-ci rcu iting.
&,CAUTION The battery contains sul furic acid (electrolyte). Contact ing
with ski n or eyes may cause severe burns. If such case occurs, nu sh with
water for at least 5 minutes and call a physician immediately. Please protec-
1 \..
--
< Fuse tive clothi ng and a face shield. Keep out of reach of children. Do not use a new
battery until taking a 3D-minute wait after adding liCJuid. If the eng ine fail s to
Fig. 37 be started with the electric starter and the neulrallight is dim, use me kick-
starter to start the engine. For prolonging the serv ice, please start the eng ine
using the kick-starter when the air temperalUre is lower. Charge the bauery at
a rate less than J A for J 0- 15 hours if necessary. For further delails, refer to
Operating Instruct ions of Battery.
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 TROUBLESHOOTING, STORAGE AND OPTIONAL PARTS
TROUBLESHOOTING Prevent the murner from gelling in water. the spark plug from being welled
If the engine fails to start. do checks as follow s: down when washing the vehicle.
I. Is there enough fuel in the tank? Storage
2. Is fuel reaching the carburetor from the tank cock? Take some me'lsures as following when subjecting the vehicle to 6O-day or
3. Disconnect the fucllinc from the carburetor, set the lank cock to "'tf" more storage.
position,and see if fuel nows out? I. Empty fuel inside the fuel tank. carburetor and other pipes.
4. If OK, check the ignition system. 2. Drive off the spark plug, pour a bit of engine oil SAEI5W/40-SE into the
",-CAUT ION Do not allow fuel to now at will. Fuel should be collected engine. Tum off the emergency sw itch and operate the starter bUllon several
in the retainer.Do not smoke or allow flames or sparks in the area times to scalier evenly the oi l inside the cyl inder.
where the engine is subjected to the check. 3. Remove the drive chain, clean and oil it
5. Remove the spark plug from the cylinder head. and connect it with the 4. Lubricate all of the controll ing cables.
spark plug cap, 5. Block up the vehicle frame so that both the wheels clear the ground.
6. Fix the spark plug on the vehicle body. Tum the ignition switch on. set the 6. Seal the murner outlet with a plastic bag to prevent the former again st
emergency switch to" () " position. Press the start bUllon, and sec if there moisture.
are sparks at the e lectrode gap of the spark plug. If there are no sparks, see 7. Coat all surfaces of bare metal with ,1 thin layer of rust-resisting oil if the
your dealer for help. motorcycle is slOred in moist and salty regions.
",CAUTION 8. Dismantle the ballery and store in a dry, cool and we ll -ventilated place.
Do not conduct the said check by fixing the spark near to the cyliner Charg~ the balle'Y.monl~lx in course of storage.
head. Otherwise, gas in the cylinder may ignite by sparks. REMOVAL j<'ROM STORAGE
For safety's sake, it is better to connect the metal portion of spark plug After long-tenn storing the motorcycle. check. adjust and service it according
outer housl!!.g with bare metal of vehicle body. to requirements stated in the manual to make sure the motorcycle funclions
CLEANING AND STORAGE P.r<l~rl.x. Trylhe vehicle at low ~ed in a safe riding area away from traffic .
Cleaning ANTi-TtlliFf DEVICJ;; (Optional)
I. Check if the spark plug and inlets are installed or pluged securely before I. Before usi ng the remote-controller. be sure that the vehicle is in neutral and
cleaning the vehicle. the ignition switch is turned off.
2. Hose the vehicle completely. 2. Electric starting by the remole-controller only warms up the engine. and
3. Dry the motorcycle using a soft cloth or sponge. the engine will SlOp aUlOmatically in 2.5 minutes.
4. Lubricate the drive chain immediately after washing and drying to prevent 3. Don't apply both the front and rear brakes after starting the eng ine by the
surfaces from getting rusty . remote-controller and before turning on the ignition switch. Olherwise. the
5. Start the engine, and allow it to run for several minutes. starting motor will run once more .
CAUTION Hi gh-pressure water can damage certain parts such as wheel 4. Don't ride without the key to insure that the function of anti-theft i5.
bearings, front fork , brakes, seal of transmission, electric equ ipmen t, etc. reliable enough.
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 ELECTRIC DIAGRAM

SPEED LIGHTING EMERGENCY IGNITION IGNITION RR. BRAKE SIARTING BAnERY

SENSOR SW STARTER SW. SW. IGNfI!ON COil 2 IGNITION SW RELAY
BunON COIL 1 CONTROlLER

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FR. WINKER. RH ~
Sb- ~ 2 TO EN GINE CASE
12Y·l0W
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FR. WINKER. lH
12Y-l0W o-
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12V-5W
ODOMETER
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BI G STOP /I AlLUGHT

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NEUTRAL IND1C . • 12Y-21/5W
TURN SIGNAL lNDIC •. RH
Sb
TURN SIGNAL INDIC.. LH G RR. WINKER. LH
HI-BEAM INDIe. -0-- Lj- 0, -0:>-1-06 12Y-lOW

UCENSE LIGHT

~w " -<30---'0 12Y-5W

HEADUGHT ~.;+-

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12Y-35/35W
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POSITION LIGHT G-
12Y-5W TOFRAM
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lu' il I I I I I LgG GIBI "
BI G:::o ...... BI
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1=@ill;iIIUIUI~ PASSING HORN SIDE SIAND DIODE

DIMMER TURN SIGNAL SIGNAL HORN FLASHING AUXILIARY FR. BRAKE ~W. CLUTCH
SW. SW. SW. BunON RelAY REALY SW. SW. MAGNETO RECTIFIER

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 SPECIFICATIONS
Vehicle Model 250-8 Ignition system TCI
I. DIMENSIONS AND PERFORMANCE Max. power, kW/r/min 13/8000
Overall dim.( L x B x H) 2250 x 850 x 1140 mm Max. torque, N . m/r/min 19/6000
Steering bar angle 43 ° Engincoil SAEI5W/40-SE
Ground clearance 150 mm Engine oi l capacity 1.2 L
Turning ci rcle dia. 4800 111m Lubrication Press/sp lash
Wheelbase 1495 mill Fuel Unleaded gasoline with RQ-93 or higher
Kerb weight 163 kg
Clu tch type Wet mulLi-platc
Max. weight capacity 150 kg
Transmission 5-speed. constant mesh
Top design speed ;;> 100 kmlh
Primary reduction ratio ( 0)) 3. 130
Eoon.speedfueICOll'<. < 2.26U lOOkm Gear ratio. lSI ( I I) 2.642
Grade ability ;> 20°
2nd ( I, ) 1.684
Front lyre size/pressu re 3.0- 18/200kPa
3rd ( I,) 1.260
Rear lyre size/pressure 5.0- 15/225kPa
4th ( I,) 1.000
Front shock absorber Te lescopic Iype hydraulic drive
5th ( I.) 0.82 I
Rear shock absorber Coil spring-dampened
Fron t brake type Di sc
Final reduction ratio ( I F) 2.8 12
Rear brake type Drum 3. ELECTRIC EQUIPMENT
Fuel tank capaci ty 14 L Battery 12VIOAh
2. ENGINE Spark plug A7TC
Model 2V49FMM Headl ight 12V-35W/35W
Type Twin-cylinder, 4-stroke, ai r-coiled Winker 2V- I OW
Bore )C Stroke 49 )( 66mm Tail/stop light 12V-5WI2IW
Displacement 248.9 ml Horn 12V
Compression ralio 10.0: 1 Odometer light 12V-3W
Starting mode Electric-starter Fuse 20A
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